Method of forming rod-like paper articles



April 1955 J- v. ATANASOFF 2,706,933

METHOD OF FORMING ROD-LIKE PAPER ARTICLES Fi led Aug. 27, 1951 3 Shets-Sheet l ATTORNEYS April 26, 1955 J. v. ATANASOFF METHOD OF FORMING ROD-LIKE PAPER ARTICLES 3 Sheets-Sheet 2 Filed Aug. 27, 1951 INVENTOR W zyww 6,4, $M w ATTORNE 33 April 1955 J, v. ATANASOFF 2,706,933

METHOD OF FORMING ROD-LIKE PAPER ARTICLES Filed Aug. 27, 1951 3 Sheets-Sheet 3 Eli INVENTOR BY Luna-W, 64, [Male/+10% ATTORNEYS United States Patent METHOD OF FORMING ROD-LIKE PAPER ARTICLES John V. Atanasofl, Fulton, Md., assignor t0 Communications Research, Inc., Clarksville, Md., a corporation of Maryland Application August 27, 1951, Serial No. 243,858 8 Claims. (Cl. 93-1) This invention relates to a rod-like member or article fabricated of paper and particularly to an article of this type which may be utilized in the confectionery art in the same manner that the well-known Wooden confectionery stick is employed, one end portion thereof to comprise a support or core upon which a body of ice cream, candy duced in quantity and in a continuous manner.

The improved paper stick is not only less costly to manufacture than those fabricated of wood and which have heretofore been so widely used, but also possesses a number of advantages which render it decidedly superior should have in order to accomplish its intended functions in a satisfactory manner, it does not have such strength as a column that it can injure the mouth of a child who falls to the ground while eating the confectionery which the stick supports. Accidents of this nature rather frequently occur and, where the well known Wooden stick is in the child's mouth, may be of serious character, being rendered especially so by reason of the fact that the grain of the wooden stick runs generally longitudinally of that stick so that the stick may split longitudinally and a sharply pointed portion result which may well be able to penetrate deeply into the roof of the mouth if sufficient pressure is applied.

The improved paper stick contemplated by the invention can be formed in such manner as to be relatively large in transverse section for a given amount of paper employed in its manufacture and the preferred form of the invention contemplates the fabrication of one portion of the paper web from which the stick is formed into a cellular core, the remainder of the paper web being wound about this core to form a tubular enclosure therefor. By forming as a preliminary step a cellular core comprising a number of relatively folded panels of the paper web from which the stick is made, and thereafter winding about this pro-formed core a sufficient amount of paper in sheet form to closely support the core and cause it to have the necessary stiffness as a column, a very satisfactory low-cost stick may be made, such stick having confectionery trade.

Adhesives of various kinds may be employed to secure the various panels of the stick to each other so as to form a rigid structure. Thermosetting or thermoplastic materials may be employed in lieu of ordinary adhesives to provide greater strength if desired and adhesives of water-proof nature may be employed to increase the resistance of the resultant stick to the weakening effect of moisture.

A novel method of forming the stick is utilized, this method being of continuous character and contemplating the advancement of a web of paper along a fixed path at a desired rate, the web being acted upon at each of a successive series of stations along its path of movement and all of the stick forming operations being accomplished as the Web successively passes these stations, the completed stick issuing as a continuously advancing member after the last operation has having been subjected to an shaping operations, is trans responsive materials and, if ing mstrumentality may be been accomplished and, after y desired final compacting or versely sheared into units of necessary or desired, a coolutilized to quickly cool the thermoplastic or thermosetting material after it has been accordance with the nature of upon, the nature of the adthe design of the stick to be cross sectional shape and diform a plurality of narrow, longitudinally extending interconnected panels. to form the core, which is section.

These panels are then relatively folded preferably of zig-zag cross for forming the panels and folding them may include devices for scoring or creasing the paper along parallel lines as lowed by means for ner, closely adjacent the inner and along parallel lines to performing the folding the creasing and panel folding operations a preliminary operation, foloperations, or may be perbe in the nature of a crimpportion or band of the adform the cellular core the also in a continuous manterminal panel of the core facilitatefolding over of the of an adjacent strip the width of which, when added to the width of the edge panel, comprises a strip coextensive in width with that of the cellular core.

The operation of folding over onto the adhesive coated surface of the web the previously formed cellular core is accomplished by stationary panel, through an angle of means positioned adjacent the thus bringing the core into full contact with the previously coated band of the web, the edge panel which being moved into right-angular ing this operation. iently be performed operation described.

The cellular core and with which it has been the br passes between rollers which connects the core and web relation to the web dur- The folding operation may convenprior to the time of the apunderlying band of the web ought into engagement then further establishes firm contact between core and web and simultaneously forms two further parallel creases in th immediately adjacent the fo row band or panel being th constitute the second edge e web, the first of these being lded over core, a second naredge panel and an adjacent Width of the web which is coextensive with the core, the application of the adhesive at this station proceeding also in a continuous manner.

At a further station that edge of the traveling web which includes the folded over core encounters a folding means which effects the gradual folding over through 180 of the previously formed rib-like structure comprising the core and the band or side panel to which one side of the core has been adhesively secured, the second edge panel being simultaneously brought into position. At this point there has been completed a rod-like member comprising a cellular core and four enclosing panels, two side panels which may be relatively wide, and two edge panels which are preferably quite narrow, the core thus being completely enclosed. Such a member if severed into lengths might be of utility for certain purposes but where a stick to be used in the confectionery trade is the ultimate article desired, and the web is of relatively thin paper, it is important to continue the procedure, which is in the nature of a winding operation, until the core is enclosed within a tubular structure each wall of which is several plies in thickness. Therefore the web. is made sufficiently wide initially to provide the necessary material for the formation of a tubular envelope of the desired number of thicknesses and the operation of turning over the first formed tubular core is continued until the web is completely consumed.

At the conclusion of the folding operation the resultant advancing stick may be acted upon by rollers which further define its shape in transverse section and compact its structure, these further rolling operations being especially desirable under some circumstances, finally it is sheared to length, its ends being rounded or cut square as desired. The operations described can be performed quite rapidly and the output of a single machine constructed to accomplish the method will be very great per unit of time. The cost of production is extremely low and the resultant article, while being in all respects eminently suited for the intended purpose, much less costly than the wooden stick heretofore so widely employed, as well as having the enumerated advantages.

In the accompanying drawings elements of a machine or apparatus for acting upon a moving paper web in the specified manner are illustrated and, by means of di agrams, the various steps of the method are indicated. It will be understood that the method may be varied in certain respects in order to accomplish the manufacture of rod-like paper articles which are intended to be put to uses other than as confectionery sticks and that sticks having cross sections which are not rectangular may be produced by slightly varying the means employed and slightly modifying the steps of the method, both method and article being subject to modification without departure from the invention.

In the drawings:

Figure 1 is a perspective view tended for use as a confectionery lowing the novel method;

Figure 2 is a section on line 2-2 of Figure 1, being a transverse section through the stick but on a larger scale and with panels spaced apart so that they may be individually perceived;

Figure 3 is in the nature of a diagram indicating a paper web and the successive operations performed upon thaiweb in order to accomplish the manufacture of the stic Figure 4 is a second diagram intended to further illustrate the nature of the operations performed on the web, station by station;

Figure 5 is a plan view showing a portion of the moving paper web and several of the stationary instrumentalities which act upon it, including means for forming the cellular core, applying adhesive, and folding over the core thus formed;

Figure 6 shows in side elevation the web and elements illustrated in Figure 5;

Figure 7 is a section on line 7-7 of Figure 5; Figure 8 is a section on line 8-8 of Figure 5:

Figures 9, and 11 are sections on lines 9-9, 10-10 and 1111, respectively, of Figure 5;

Figure 12 is a section on line 12-12 of Figure 5; Figure 13 is a similar section taken at a subsequent tation along the length of the web, for instance a sec ion long the line 13-13 of Figure 16;

of a rod-like article instick, produced by fol- Figure 14 is a perspective view of portion of an apparatus for finally compacting and shaping the issuing stick prior to its severance into short lengths;

Figure 15 is a section on line 15-45 of Figure 14; and

Figure 16 is a side elevation of the shaping and compacting devices of Figures 14 and 15 together with certain of the means for accomplishing the final turning operations.

The web of paper from which the stick is formed in a continuous manner is indicated at 10 and, while the elements of the machine for performing the method may be considerably varied in position and character, it is preferred that the web shall move along a horizontal path in the direction of arrow P (Figure 4) and that suitable means be provided for positively advancing this web at a uniform rate and for preventing it from deviating laterally from the desired path of advancement. The upper roller of a cooperating pair of driven paper engaging and advancing rollers is indicated at R in Figure 5, and there may be a number of such pairs of rollers. The normal width of the oncoming web is that which may be observed at station A in Figure 3. At station B one margin of the web pasess between parallel rollers 11 and 12, the nature of which may be most clearly observed in Figure 7, and this margin is acted upon by the cooperating sharply grooved portions 11 and 12 of the rollers in such manner as to form a serpentine or crimped section which includes a number of panels, for instance ten as shown in Figure 7, adjacent panels being angularly disposed relatively to each other and alternate panels approximately parallel, the panels being of approximately the same width, this being the first operation performed in the fabrication of the cellular core unless, by reason of the nature of the paper, it is desirable to previously score the web along parallel lines so as to form lines or creases to facilitate the subsequent relative folding of the panels.

Simultaneously with the operation accomplished by the rollers 11 and 12 in the forming of the core panels, which are given the reference numeral 14, two crease or fold lines are formed immediately adjacent the innermost core panel 14, these creases being indicated in dotted lines at 15 and 16 in Figure 3 and in Figures 7 to 12 inclusive, the scorings or fold lines 15 and 16 being formed by the cooperation of circular ridges 17 and 18 on roller 12 which enter correspondingly shaped grooves formed in roller 11. The narrow band of paper between creases 15 and 16 ultimately becomes one of the edge panels immediately adjacent the cellular core, and which panel is indicated at 19.

In the average case it will be found to be undesirable to form the cellular core at one operation, which may be too drastic for the qualtiy of the paper undergoing fabrication, and formation of the serpentine core may therefore be accomplished at two or more stations, the operation at station B being the initial operation and the operation being completed, in the form of the invention selected by way of example, by the rollers at station C, shown in Figure 8 of the drawings. It will be observed from an inspection of Figure 5 that the roll pass at station C narrows the core and increases its depth, the ridges and grooves of the rollers 20 and 21 at this station being narrower and deeper than those at the preceding station, likewise the narrow band 19, which is to form the initial edge panel, is curved to a smaller radius and the creases emphasized, the circular edges 23 and 24 of the roller 21 being somewhat larger in diameter than the corresponding ridges 17 and 18 of roller 12 and being slightly closer together. The margin of the web which has thus been acted upon at stations B and C is a zig-zag structure comprising ten relatively folded panels and, as the web continues to advance, this structure or cellular core is repeatedly turned or folded over toward and onto the fiat portion of the web, being thus continuously wound into the remainder of the web. The initial winding operation must, of course, be performed in such manner that the panels will not be straightened out and the cellular aspect of the core lost either wholly or in part and to obtain this objective the core is caused to enter a tubular cam member indicated at 30 with elongated interior blades or ridges 31 which follow the curvature of the cam and serve to maintain the angularity cf the panels and the integrity of the core as it passes through the tubular cam.

In Figures 9, l0 and 11 of the drawings the traveling core is shown in three successive positions as it is turned through an angle of about its inner edge toward 2,706,983 6 and into contact with the upper surface of the traveling the stick and cylindrical end portions which have periphweb 10 and it will be observed from these three figures eral contact with each other, for roller spacing purposes, of the drawings that, as the core structure is overturned and annular inner surfaces which engage the edge panels the edge panel 19 straightens outuntil finally, when the of the stick. Intermediate stations L and N, two edge core structure has been turned through 180 and is in con- 5 panel engaging rollers 55 and 56 may be positioned with tact with the upper surface of the web the panel 19 is advantage. Other arrangements of stick sizing and finishdisposed at a right angle to the web, as shown in Figure ing instrumentalities may be employed, those shown being 12 and at station D in Figure 4. Prior to contact of illustrated by way of example. the overturned core with the web against the immediately As Will be clear also, to one skilled in the art, the imadjacent mutually facing margin of the fiat web an adhe- 10 proved stick or rod-like article may be fabricated with the sive of suitable character is applied to such margin by aid of means which is specifically different from that any appropriate means. shown but which is nevertheless capable of accomplishing There is shown in Figure 5 of the drawings an adhesive the several steps of the method and producing the desired applicator 33, which may be a roller continuously suparticle. plied with adhesive in a suitable manner. Thus the 15 Having thus described the invention, what is claimed ridges of the core are brought into contact with the preas new and desired to e secured by Letters Patent is viously coated area of the web as the core enters the The method of forming a rod-like paper article pass between rollers 34 and 35 of Figure 12 and in passwhich comprises advancing an elongated web of sheet ing t rough are pressed tightly against the web, the lower material in the direction of its length acting upon a latroller 34 having a cylindrical end portion 34a which superal portion of the advancing web to form said portion ports the flat band of the web and the upper roller 35 into a plurality of narrow longitudinally extending adhaving the grooved portion 35a which bears down upon jacent panels, manipulating said panels to form a celluthe core, maintains the integrity of the core, and presses lar core, and relatively rotating core and web as the w b the peaks of the ribs of the core closely against the adheadvances, to enclose the core in the remainder of the web sive coated surface of the web At t e same time, and 2. The method of forming a rod-like paper article due to the cooperative action of circular creasing edges which comprises advancing an elongated web of sheet 37 and 38 formed on roller 35, and corresponding grooves material in the direction of its length acting upon a latformed in roller 34 a further edge panel is defined by eral portion of the advancing web to form said portion parallel creases, thus facilitating the operation of again into a plurality of interc nnect d HaII W, longi udinally overturning the core with attached panel portion and extending and relatively foldable panels, relatively foldbringing about the formation of a stick of truly rectangu-' ing said panels to form a cellular core and enclosing the lar cross section. core in the remainder of the web by relatively rotating Similar operations are performed at the stations which the core and the remainder of the web. fo low, i. e. stations E, F, G, H and I, which are indicated 3. The method of forming a rod-like paper article in Figure 3 of the drawings, adhesive being applied prior which comprises advancing an elongated web of sheet to the completion of the folding operation in each ir material in the direction of its length acting upon a latstance, a further edge panel being defined by parallel eral portion of the advancing web to form said portion creases, and light pressure being applied to the freshly eole eomprlsmg a P y 0f lehgltudlhally folded over partially completed stick each subsequent tending narrow, interconnected, angularly disposed panels pair of rollers, of which examples are indicated at 40 and 40 of approximately equal width, and closely enveloping 41 in Figure 13, being provided with a web supporting said core, while maintaining it constant in cross section, cylindrical end 40a, a stick engaging cylindrical end 41a in th r mainder of the web. of reduced diameter, annular ridges 42 and 43 formed 4 e method of forming a rod-like paper article on roller 41 being adapted to enter grooves 44 and 45 which COITIPIIS6S. advancing an elongated web of sheet of roller 40 in further creasing and defining an edge panel. 45 m l n the direction Of its length, Continuously acting It will be appreciated that as the overall dimensions of P One lateral Portion thereof to m a Cellular core the stick increase due to the winding operation the edge of g formatiOn a d nding Said Core into the repanels must be of increasing width and this is accom- Inalhdel f the Sheet plished by more widely spacing the scoring edges 42 and The method of fQfmmg a rod-like P P article 43 of roller 41 as the terminal station is approached. which comprises advancing an elongated paper web in In Figure 4 the several overturning operations perthe dlfeetloh of its length, acting p a lateral margin formed are indicated diagrammatically and from an inthereof as it Passes a F forming Station to n inuspection of this figure the nature of the winding operation Ously form a Core of afelmation, gradually rotat- Will be more fully appreciated. It is, of course, necesmg the core as the Web further advan es to him the sary to space the stations apart from each other a disame into contact with the web and thereafter contance Which will permit the folding operation between l f e rotation of core and that Portion of the W stations to be accomplished without over-stressing and which s in contact with the core until the core is enpossibly rupturing the paper. For instance, one margin closed In a 'p y Coveringof the core, in passing through the cam 30, will move The method of fofmihg a r(Id-like l' l article along a path which is longer than the opposite margin and which c mpri es; advancing an elongated paper web in unless the cam 30 is of suflicient length this margin which the direction of its length acting 1113011 a lateral margin is, of course, the outer margin, might be over-stretched thereof as it passes a core forming station to continuously an roken Hen the ev al core overturning cams form a core of substantially rectangular cross section must be of a length which is found suitable, having in f an adlaeeht Panel the Wldth of Whleh 15 equal to the Build the nature of the a ei WlIlCh 15 bein fabricated. thickness of the core and gradually turning the Core angu- F paper f fi qual ty th d t b t stations lariy as it advances with the web to bring the side of the h ld b t l th approximately 10 i h h core nto contact with the web and the panel into angular paper sticks approximately three-eighths inch in width relation to the are being fabricated. For paper which is more stretch- The method of femllhg a fed-like P p article able the distance between stations may be less, and one 7 W hleh e0mPF1S eS advancing an l gat d paper web in the skilled in the art would readily appreciate the fact that dlleetleh 9 Its length, acting p a lateral margin a machine may be readily devised which will accomplish thereof as it passes a core forming station to continuously the desired function without overstraining and weakenhim a cor e 01 Substantially rectangular Cross Section a ing any portion of the paper in the process 0f forming the an ad acent panel the Width Of Which is equal to the thicki ness of the core applying an adhesive to the surface of The Stick will have been fully Wound when it issues said panel and an ad acent band of the web coextensive in from between the two cooperating rollers at station K but Wldth i the Web, and gradually turning the Core anguit may be desirable to pass it between final shaping and yf It advahee$ with the Web to bring the Side Of the compacting d i b f cutting it i t l th parcore into contact with the web and the panel into angular ticularly if the adhesive has not hardened. Three roll TelatlOH t0 the passes are indicated, respectively, at stations L, M, and The method of forming a Ted-like P p article N, Figure 16. As shown in Figures 14 and 15 the cowhich comprises advancing an elongated paper web in the o erating rollers 50 and 51 and 52 and 53 at tation L direction of its length, forming in a lateral marginal porand N, respectively, have reduced central cylindrical portions which bear upon the upper and lower surfaces of the web advances, to form a core, and thereafter repeatedly rotating the core about axes parallel to the direction of movement of the web, respectively, as the web and core advance, to wind the web wholly about the core.

References Cited in the file of this patent UNITED STATES PATENTS 1,085,948 Smith Feb. 3, 1914 

1. THE METHOD OF FORMING A ROD-LIKE PAPER ARTICLE WHICH COMPRISES ADVANCING AN ELONGATED WEB OF SHEET MATERIAL IN THE DIRECTION OF ITS LENGTH, ACTING UPON A LATERAL PORTION OF THE ADVANCING WEB TO FORM SAID PORTION INTO A PLURALITY OF NARROW LONGITUDINALLY EXTENDING ADJACENT PANELS, MANIPULATING SAID PANELS TO FORM A CELLULAR CORE, AND RELATIVELY ROTATING CORE AND WEB AS THE WEB ADVANCES, TO ENCLOSE THE CORE IN THE REMAINDER OF THE WEB. 